Planetary gear reducers and gearmotors

Transcription

1 Products EP Planetary gear reducers and gearmotors Edition March 2013

2 Contents Features and Benefits Product range Symbols Units of measure 1. Introduction Design principles 1.2 Planetary gear reducer main features 1.3 Competitive advantages 1.4 Application fields 1.5 Main structural features 2. Design features Ordering code 2.2 Technical details 2.3 Selection 2.4 Gearmotor selection 2.5 Gear reducer selection 3. Selection tables In line gearmotor selection tables 3.2 Bevel helical gearmotor selection tables 3.3 In line gear reducer selection tables 3.4 Bevel helical gear reducer selection tables 4. Summary of performance, dimensions and details 4.1 Sizes 001A A 5. Further options 5.1 Sizes 022A, 031A, 043A Sizes 001A A - Main inch dimensions 6. Mounting positions, oil quantities and tanks 6.1 Sizes 001A A 7. Input, options and cooling systems Hydraulic motor input flange 7.2 Hydraulic motor input flange dimensions 7.3 NEMA motor input flange 7.4 Input side options 7.5 Cooling systems 8. Installation and maintenance General information 8.2 How supplied 8.3 Name plate 8.4 Transport, handling and storage 8.5 Installation of gear reducer 8.6 Installation 8.7 Universal flange adapter 8.8 Motor mounting or replacement 8.9 Lubrication 8.10 Commissioning 8.11 Cooling unit system 8.12 Backstop 8.13 Maintenance 8.14 Troubles: causes and corrective actions 8.15 Technical formulae Catalog Ordering code Worldwide Sale and Service Network EP Edition March 2013 III

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4 Your worldwide partner for high quality solutions Who we are In brief: 1953 Year of foundation as family business and today still privately owned 70 s First in Italy to adopt a complete modular system for gear reducers with cylindrical and bevel gears; first in Rossi in the 70 s Italy to adopt case-hardened, tempered, ground gear pairs on parallel and right angle shaft gear reducers 80 s Worm gear reducers and gearmotors with universal mounting, single-piece housing and ZI involute profile; extension of the direct sales organization abroad with the facilities of the German, English, French and Spanish subsidiaries. 90 s Parallel and right angle shaft gear reducers and gearmotors with universal mounting and single-piece housing; first transmission manufacturer in Italy and second in Europe to obtain Quality System Certification ISO The only one to offer 3-year-warranty 1997 Acquisition of Seimec (Rossi Motor Division) Rossi Motor Division 2002 Acquisition of SMEI (Rossi Planetary Gear Reducer Division, WIND) 2003 ISO Standard (Vision 2000) 2004 New affiliated company in U.S.A. Habasit acquires important share in Rossi, to reinforce global presence and develop growth strategy 2009 (July) Habasit Holding owns 100% Rossi Rossi Planetary Gear Reducer Division 2010 Logo and Company name change: from Rossi Motoriduttori to Rossi S.p.A. Rossi Industrial Gear Reducer Division, today For more than 50 years Rossi has been developing its business in the most demanding applications to become one of the world s leading gearmotor manufacturers suitable for critical machines. Even in the toughest environment, Rossi is recognized for providing state of the art technology, solid value, and commitment to its customers. EP Edition March 2013 V

5 What we do Rossi wide standard product range and design, allowing a universal and flexible application, means we can provide the right solution for every application and grant a 3 year warranty worldwide. Gearmotors Type of gear Worm gearmotors Standardfit worm gearmotors Coaxial gearmotors Standardfit coaxial gearmotors Helical and bevel-helical gearmotors Catalog A AS E ES G Planetary (coaxial and right angle shaft) gearmotors EP Gear reducer Type of gear Worm gear units Helical gear units Bevel-Helical gear units Catalog A G G Heavy duty helical gear units H Heavy duty bevel-helical gear units H Planetary (coaxial and right angle shaft) gear units Right angle shaft gear units Shaft mounted helical gear units EP L P VI EP Edition March 2013

6 Motors Type Asynchronous three-phase high efficiency and premium efficiency motors Standard and high efficiency brake motors Heavy duty roller table motors Catalog TX TX S Motion control Type Worm, coaxial, parallel and right angle shaft servo gear units Catalog SR Low backlash planetary servo gear units SM Specific industrial segments Type Extruders, Parallel shaft gear reducers and gearmotors Catalog GX Wind drives, Pitch and Yaw drives EPW Slewing drives EPS Combined gear reducer EP Heavy duty, Drive units on swing base RE HyCLEAN solution (food and beverage, chemical) Heavy duty roller table motors HyCLEAN S EP Edition March 2013 VII

7 Where you can find us Close to our customers in all five continents, with a direct sales system granting excellence in service: visit our new website for your country reference. We are where you need us to be. What we believe in Choosing the drive with the right technical specifications is vital for reliability and economy. We believe in integrity, ethical behavior, knowledge, imagination, innovation, good teamwork and above all customer focus: these are some of Rossi s major key success factors. Rossi is a reliable company with the right flexibility and knowhow to respond to all market requests, all over the world, in all application fields, without leaving aside its commitment for the environment and value on human safety, to protect everyone s future. What we can do for you A highly skilled specialist team in different fields, Industry Segment Managers providing customers with the right support to find the best solution suitable for your demands, and accompany you step by step alongside the whole supply. Who you can call A well-organized after-sale service providing problem solving in the quickest possible way Rossi for You portal, allowing customers to have 24/7 access to all the documentations concerning Rossi supplies, news and order tracking in real time. Worldwide standard certified to: IEC, UNEL, UNI, DIN, ATEX, UL, CSA, NEMA, MEPS, EISA, ErP (IE2, IE3)... What you can do for us You are at the center for Rossi: that s why we want you to give us suggestions on our work, to inform us about news in your sector and anything that allows us to give you better service, from all points of view. You are for us a partner which can contribute to our ever evolving improvements in all fields. VIII EP Edition March 2013

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9 Features and benefits Rational, modern, and essential design, high stiffness Design and calculation of every single component Wide range of possible versions and low speed shaft designs Regular and closer size steps IEC, NEMA and main hydraulic motor adapters High performance, guaranteed for long life, extremely easy maintenance for the end user Torque unit cost reduction Innovative solutions responding to the real application needs of most demanding industrial sectors Customer-tailored solutions for easiest and most costeffective design and installation for repairs (revamping and new installations) Precise and aimed selections for important energy efficiency saving Wide range of accessories and designs, specifically studied for every single size Fluorinated seal rings Lifting hooks as standard Magnetic plugs with OR Enhanced internal lubrication New support of planet gears The application solution is facilitated by several designs foreseen in the catalog, also studied in order not to limit performance Improved reliability of oil seals Easy and safe handling Nearly maintenance-free Reduction of running temperatures Increased smooth and even running Rational position of oil level and drain plugs Extra-Large plugs Improved thermal capacity Simplified and optimized installation and maintenance Limited use of expansion tanks Possibility to install integrated or independent oil cooling devices Brand new solutions for synchronized and counter revolving applications Enhanced oil circulation X EP Edition March 2013

10 Features and benefits Competent assistance and technical support during design/selection activities performance, reliability, cost-efficiency Product tested at assembly line end All external gears are ground Gear reducer supplied filled with PAO (polyalphaolefin) synthetic oil up to size 021A reliability Easier to fit Easy to service Oil Oil Oil Oil Oil Reduced maintenance EP Edition March 2013 XI

11 Product range Size M N2 [N m], M 2max [N m] Fr2 1) [N] (C...), Fr2 1) [N] (S...) Train of gears - Planetary In Line i N 1EL 2EL 3EL 4EL 3, ,1 12, A 1 600, , A 2 240, , A 3 150, , A 4 500, , A 6 300, , A 9 000, , A , , A , , A , , A , , A , , A , , A , , A , , ) Radial loads valid for cylindrical shaft end (C...) and splined shaft end (S...), respectively. XII EP Edition March 2013

12 Product range Size M N2 [N m], M 2max [N m] Fr2 1) [N] (C...), Fr2 1) [N] (S...) Train of gears - Planetary Bevel Helical i N 2EB 3EB 4EB ,5 31, A 1 600, , A 2 240, , A 3 150, , A 4 500, , A 6 300, , A 9 000, , A , , A , , A , , A , , A , , A , , A , , A , , ) Radial loads valid for cylindrical shaft end (C...) and splined shaft end (S...), respectively. EP Edition March 2013 XIII

13 Symbols Danger The paragraphs marked with symbols shown below contain dispositions to be strictly respected in order to assure personal safety and to avoid any heavy damages to the machine or to the system (e.g.: works on live parts, on lifting machines, etc.); the responsible for the installation or maintenance must scrupulously follow all instructions contained in present handbook. Dangerous situation, the operator must take all safety measures to avoid serious damage or injury Do not lifting. Lifting and handling incorrect Suspended loads. Do not stand under suspended loads General Alternative output design M Shaft subjected to torque only M F 2 Shaft subjected to both torque and radial load Mass 30 N m Tightening torque ch.7 refer to chapter reference number XIV EP Edition March 2013

14 Units of measure Symbol Units of measure Notes In the catalog dimensions mm SI system 1) C t2 gear reducer torsional stiffness referred to the low speed shaft N m/ ' f frequency Hz fs service factor ft thermal factor F force N F r, F a radial loads and axial loads N f L service life factor g acceleration of gravity m/s 2 standard 9,81 m/s 2 G weight (weight force) N i transmission ratio i= n 1 n 2 J moment of inertia kg m 2 L h bearing life h m mass kg M torque N m 1 kgf m 9,81 N m M N2 nominal output torque of gear reducer, for a specific angular velocity N m M 2U maximum value of output torque, for a specific output design N m M N2max maximum value of nominal output torque, for a specific transmission ratio N m M N2,ref nominal output torque referred to n 2 L h N m M 2 nominal output torque of gear reducer, derived from input power applied N m M 2max maximum torque admissible on gear reducer low speed shaft N m M 2eq equivalent torque in the cycle, referred to gear reducer low speed shaft N m n angular speed min -1 1 min -1 0,105 rad/s n n 2 n low speed shaft in the interval 1... n in the operation cycle min -1 P power kw W 1 CV 736 W 0,736 kw Pt thermal power kw P 1 input power applied on gear reducer kw P N2 nominal power produced by gear reducer, referred to low speed shaft kw P 1th equival. thermal power in the operation cycle, applied on gear reducer high speed shaft kw Q R gear reducer oil quantity at correct level l t Celsius temperature C t time s t 1... t n duration of load cycles 1... n h U voltage V W work, energy MJ J z frequency of starting starts/h angular acceleration rad/s 2 V g displacement per revolution cm 3 q v input flow l/min -1 efficiency v volumetric efficiency mh mechanical hydraulic efficiency t total efficiency ( v. mh ) plane angle rad backlash on gear reducer low speed shaft p different pressure bar angular velocity rad/s 1 rad/s 9,55 min -1 Additional indexes and other symbols ind. Definition N nominal 1 relating to high speed shaft (input) 2 relating to low speed shaft (output) max maximum min minimum eq equivalent th thermal c cycle from... to approximately equal to greater than or equal to less than or equal to Planetary gear train Ring gear (locked) Planet gear Planet carrier (low speed shaft) Sun gear (high speed shaft) 1) SI are the initials of the International Unit System, defined and approved by the General Conference on Weights and Measures as the only system of units of measure. Ref. CNR UNI (DIN NF X , BS , ISO ). UNI: Ente Nazionale Italiano di Unificazione. DIN: Deutscher Normenausschuss (DNA). ISO: International Organization for Standardization. EP Edition March 2013 XV

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16 1. Introduction 1 1 Contents 1.1 Design principles Main planetary gear reducer features Competitive advantages Application fields Main structural features 1.4 Pages EP Edition March

17 1. Introduction 1.1 Design principles 1 Rossi planetary gear reducers offer cutting edge technology solutions, exploiting the experience done on all most severe applications, with a comprehensive gear reducer range in every product typology for the industrial sectors. Since over 50 years Rossi is worldwide known for its high quality products. Applications are studied and developed thinking about the continuous development of the product in terms of: flexibility; reliability; sustainibility; total cost of use; performance; strength; user-friendly installation, transport and maintenance; service; safety. 1.2 Main planetary gear reducer features General Finishing 14 sizes with modular system; Nominal torques M N2 according to R40/6 (interval by 40%); In Line and Bevel Helical execution; fastening with through holes flange (B5), integral feet, shaft mounting with torque arm; regular size and transmission ratio steps, according to catalog; application flexibility more than excepted from catalog; modularity and adaptation; cylindrical or splined male shafts, cylindrical or splined female shafts, shaft mounting and more; comprehensive transmission ratio range from >3,5 to over ; comprehensive accessories range (more than 20 different types); direct coupling with electric, hydraulic motors, male shaft; option combined with other Rossi gear units. rational, clean and easy lines; compactness; machining quality. Design strength 1.3 Competitive advantages torque peaks resistance; resistance to radial and axial loads on shafts; high torsional stiffness; high thermal capacitance in the category. regular size and transmission ratio steps the realization of a range of machines or plants rationalizing the costs; the rational and clean design of our gear units gives a cutting edge technology, quality safety, cleaning, precision and perfection image of the machine on which they are installed. facilitating assembly and periodical maintenance; improving painting resistance; compactness (dimensions and weight); reducing the transport costs; maximizing the optimization of machine design. Modular system quick deliveries and service worldwide. excellent ratio in terms of solution reliability / cost. safety; nearly maintenance free; low use cost; low noise; increased performance with the same dimensions and weights; value and strength perception. Easy installation, transport and maintenance reduced machine assembly times; reduced maintenance times; quickness and safety in case of operation. 1.2 EP Edition March 2013

18 1. Introduction 1.4 Application fields Some examples of application fields Rossi planetary gear reducers are used in nearly all application fields requiring: high torque values; peak resistance; high transmission ratio; high efficiency; reliability and long life; reduced weights and overall dimensions. 1 Construction Mixing mills (cement, asphalt, semiliquid materials); Dryers; Crushing machines; Cranes; Mobile scaffolds. Substructures Material handling Movable gantries; Piling; Movable roofs. Movable stocks; Gantry cranes; Bridge cranes; Mobile dock cranes. Waste and sewage treatment Thickeners, clarifiers; Agitators; Rotating filters; Worm hoists. Mine and quarry machines Selectors; Crushing machines; Classifiers; Worm transport systems; Conveyors; Rotation gear reducers; Drilling and excavation machines. Steel processing machines Bending rolls; Friction calenders; Rolling mills; Extruders; Cutting machines; Conveyors. Wind energy Yaw drive gear unit; Gear reducers for pitch variation. Food industry Mixing machines; Conveyors; Fruit extractor machines; Mixers. EP Edition March

19 1. Introduction 1.5 Main structural features Modular system 1 14 sizes with modular system: Nominal torques M N2 according to R40/6 (stepped by 40%); fastening with through holes flange (B5), with integral feet, shaft mounting with torque arm; Train of gears 1, 2, 3 or 4 reduction stages for coaxial and 2, 3 or 4 stages for bevel helical design (5 stages on request); nominal transmission ratios to R 20 (3, ) for coaxial, R 20 ( ) for bevel helical; external gear pair made of casehardened and hardened steel; internal gearing made of nitrided steel; cylindrical spur gears with ground profile and flank modification; GLEASON spiral bevel gear pairs with ground profile; floating or supported planet carrier in through hardened steel or nodular cast iron according to gear reducer size; Bearings Housing low speed shaft, according to gear reducer size: taper roller bearings or spherical roller bearings for cylindrical shaft end and splined shaft; taper roller bearing or full complement cylindrical roller bearing for hollow shaft with shrink disc and flange shaft; ball bearings or full complement cylindrical roller bearing for splined hollow shaft and hollow with keyway; high speed shaft: ball or cylindrical roller bearings according to sizes; planet gears: full complement roller bearings for the highest support stifness; nodular cast iron housing; Lubrication internal protection in synthetic paint appropriate for resistance to mineral or to polyalphaolefines synthetic oil (PAO); oil bath lubrication; PAO based synthetic oil included in the supply for sizes 001A A (see ch. 8.6) with filler plug with valve; drain and level plug; sealed; 1.4 EP Edition March 2013

20 1. Introduction Painting: Products are painted with single compound ester epoxy or phenolic resin basis primer (pre-painted) and water-soluble polyacrilic dual-compound enamel colour blue RAL 5010 DIN Paint resistant to atmospheric and aggressive agents (atmospheric corrosivity category C3 according to ISO ). shaft heights to UNI (DIN , ISO ); nominal transmission ratios and main dimensions according to UNI 2016 standard numbers (DIN , ISO 3-73); toothing profile to UNI (DIN , ISO 53-74); (long or short) cylindrical shaft ends derived from UNI ISO (DIN 748, ISO/R 775); splined to DIN 5482 or DIN 5480; keys to UNI (DIN 6855-BI.1-68, ISO/R ); mounting positions derived from CEI 2-14 (DIN EN , IEC 34.7); gear load capacity verified to ISO 6336; bearing load capacity verified according to ISO EP Edition March

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